Systems, methods, and articles of manufacture for operation of an industrial machine

ABSTRACT

A control system for operation of an industrial machine includes a processor and a tangible, non-transitory, computer-readable memory communicating with the processor. The tangible, non-transitory computer-readable memory includes instructions that, in response to execution by the processor, cause the processor to perform operations including: receiving image data from an imaging device that monitors an image zone around the industrial machine, and analyzing the image data. The processor further performs operations including determining, based upon the analyzing, that the control system is functional, determining, based upon the analyzing, that the image data includes at least one of a predefined color, a predefined pattern, and a predefined shape, and transmitting a proximity signal to at least one relay module coupled between the processor and the industrial machine to halt operation of the industrial machine.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/473,214, filed Mar. 29, 2017, which claims the benefit of U.S.Provisional Patent Application No. 62/420,902 filed Nov. 11, 2016, theentire contents and disclosures of which are hereby incorporated hereinby reference in their entirety.

BACKGROUND

The subject matter disclosed herein relates to systems, methods, andarticles of manufacture for operation of an industrial machine and, moreparticularly, to systems, methods, and articles of manufacture formonitoring and controlling operation of a industrial machine in which animage zone is defined with respect to the industrial machine and inwhich the image zone is monitored for the presence of a predefinedcolor, pattern, and/or shape.

Many known industrial machines include machining tools for bending,grinding, drilling, or otherwise working large objects, or workpieces,such as various metal and wooden objects. During operation, forcesgenerated by these machines may cause a workpiece to shift or quicklymove within and outside of the machine as it is manipulated, pressed,and formed. Sometimes this is referred to as a “whip up” or “whip down”of the workpiece during operation of the machine.

To protect the operator, many conventional industrial machines areequipped with safety systems. For instance, some industrial machines areequipped with operator arm restraint straps, which the operator donsduring machine operation to maintain a safe distance from the machine.Other industrial machines require the implementation of safetyprocedures, such as procedures designed to hold the operator at aminimum safe distance from the machine during operation.

BRIEF DESCRIPTION

In one aspect, a control system for operation of an industrial machineis provided. The control system includes a processor and a tangible,non-transitory, computer-readable memory communicating with theprocessor. The tangible, non-transitory computer-readable memoryincludes instructions that, in response to execution by the processor,cause the processor to perform operations including: receiving imagedata from an imaging device that monitors an image zone around theindustrial machine, and analyzing the image data. The processor furtherperforms operations including determining, based upon the analyzing,that the control system is functional, determining, based upon theanalyzing, that the image data includes at least one of a predefinedcolor, a predefined pattern, and a predefined shape, and transmitting aproximity signal to at least one relay module coupled between theprocessor and the industrial machine to halt operation of the industrialmachine.

In another aspect, a control system for operation of an industrialmachine is provided. The control system includes a processor and atangible, non-transitory, computer-readable memory communicating withthe processor. The tangible, non-transitory computer-readable memoryincludes instructions that, in response to execution by the processor,cause the processor to perform operations including: receiving faultdetection data from the control system, analyzing the fault detectiondata, and determining, based upon the analyzing, that the control systemis functional. The processor further performs operations includingtransmitting a no fault found signal to at least one relay module of theplurality of relay modules to permit operation of the industrialmachine.

In yet another aspect, a control system for operation of an industrialmachine is provided. The control system includes a processor and a firstrelay module coupled to the processor, where the first relay module isconfigured to receive a proximity signal from the processor, and wherethe first relay module further configured to close in response to theproximity signal. The control system also includes a second relay modulecoupled to the first relay module and the processor, where the secondrelay module is configured to receive the proximity signal from thefirst relay module, and where the second relay module further configuredto close in response to the proximity signal. The control systemincludes, in addition, a third relay module coupled to the processor andthe industrial machine, where the third relay module is configured toreceive a no fault found signal from the processor and a machine cyclepermit in signal from the industrial machine, and where the third relaymodule further is configured to close in response to the no fault foundsignal. The control system also includes a fourth relay module coupledto the third relay module and the processor, where the fourth relaymodule is configured to receive the no fault found signal from theprocessor and the machine cycle permit in signal from the third relaymodule, and where the fourth relay module is configured to close inresponse to the no fault found signal and the machine cycle permit insignal.

In yet another aspect, a control system for operation of an industrialmachine is provided. The control system includes a processor and atangible, non-transitory, computer-readable memory communicating withthe processor. The tangible, non-transitory computer-readable memoryincludes instructions that, in response to execution by the processor,cause the processor to perform operations including: receiving imagedata from an imaging device that monitors an image zone around theindustrial machine, and analyzing the image data. The processor furtherperforms operations including determining, based upon the analyzing,that the image data includes at least one of a predefined color, apredefined pattern, and a predefined shape, and transmitting a proximitysignal to at least one relay module coupled between the processor andthe industrial machine to halt operation of the industrial machine. Theprocessor further performs operations including receiving faultdetection data from the control system, analyzing the fault detectiondata, and determining, based upon the analyzing, that the control systemis functional. The processor further performs operations includingtransmitting a no fault found signal to at least one relay module of theplurality of relay modules to permit operation of the industrialmachine.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an exemplary system for operation of anindustrial machine;

FIG. 2 is a block diagram of an exemplary control system of the systemshown at FIG. 1;

FIG. 3 is a flowchart illustrating an exemplary process for operation ofan industrial machine using the system shown at FIG. 1; and

FIG. 4 is a flowchart illustrating an exemplary process for monitoringoperation of an industrial machine using the system shown at FIG. 1.

Unless otherwise indicated, the drawings provided herein are meant toillustrate features of embodiments of the disclosure. These features arebelieved to be applicable in a wide variety of systems comprising one ormore embodiments of the disclosure. As such, the drawings are not meantto include all conventional features known by those of ordinary skill inthe art to be required for the practice of the embodiments disclosedherein.

DETAILED DESCRIPTION

In the following specification and the claims, reference will be made toa number of terms, which shall be defined to have the followingmeanings.

The singular forms “a”, “an”, and “the” include plural references unlessthe context clearly dictates otherwise.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where the event occurs and instances where it does not.

Approximating language, as used herein throughout the specification andclaims, may be applied to modify any quantitative representation thatcould permissibly vary without resulting in a change in the basicfunction to which it is related. Accordingly, a value modified by a termor terms, such as “about” and “substantially”, are not to be limited tothe precise value specified. In at least some instances, theapproximating language may correspond to the precision of an instrumentfor measuring the value. Here and throughout the specification andclaims, range limitations may be combined and/or interchanged, suchranges are identified and include all the sub-ranges contained thereinunless context or language indicates otherwise.

As used herein, the terms “processor” and “computer” and related terms,e.g., “processing device” and “computing device”, are not limited tojust those integrated circuits referred to in the art as a computer, butbroadly refers to a microcontroller, a microcomputer, a programmablelogic controller (PLC), an application specific integrated circuit, andother programmable circuits, and these terms are used interchangeablyherein. In the embodiments described herein, memory includes, but is notlimited to, a computer-readable medium, such as a random access memory(RAM), and a computer-readable non-volatile medium, such as flashmemory. Alternatively, a floppy disk, a compact disc-read only memory(CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc(DVD) may also be used. Also, in the embodiments described herein,additional input channels may be, but are not limited to, computerperipherals associated with a user interface such as a mouse and akeyboard. Alternatively, other computer peripherals may also be usedthat may include, for example, but not be limited to, a scanner.Furthermore, in the exemplary embodiment, additional output channels mayinclude, but not be limited to, a user interface monitor.

Further, as used herein, the terms “software” and “firmware” areinterchangeable, and include any computer program stored in memory forexecution by personal computers, workstations, clients and servers.

As used herein, the term “non-transitory computer-readable media” isintended to be representative of any tangible computer-based deviceimplemented in any method or technology for short-term and long-termstorage of information, such as, computer-readable instructions, datastructures, program modules and sub-modules, or other data in anydevice. Therefore, the methods described herein may be encoded asexecutable instructions embodied in a tangible, non-transitory, computerreadable medium, including, without limitation, a storage device and/ora memory device. Such instructions, when executed by a processor, causethe processor to perform at least a portion of the methods describedherein. Moreover, as used herein, the term “non-transitorycomputer-readable media” includes all tangible, computer-readable media,including, without limitation, non-transitory computer storage devices,including, without limitation, volatile and nonvolatile media, andremovable and non-removable media such as a firmware, physical andvirtual storage, CD-ROMs, DVDs, and any other digital source such as anetwork or the Internet, as well as yet to be developed digital means,with the sole exception being a transitory, propagating signal.

As used herein, the terms “halting” and “controlling” include stopping,partially stopping, slowing, backing up, or otherwise placing anindustrial machine in a safe operating condition.

Although the system, method, and article of manufacture described hereinare described with respect to a metal working machine, such as a pressbrake, the system, method, and article of manufacture are applicable toany type of operator controlled or monitored machine in which it isdesirable to ensure the safety of the operator and/or in whichmonitoring operations are desirable.

Accordingly, embodiments of the present disclosure relate to a system,method, and article of manufacture for operation of an industrialmachine and, more particularly, to a system, method, and article ofmanufacture for monitoring and controlling (e.g., halting) operation ofan industrial machine in which an image zone is defined with respect tothe industrial machine and in which the image zone is monitored for thepresence of a predefined color, pattern, and/or shape. To this end, andas described in greater detail below, the systems, methods, and articlesof manufacture described herein utilize a programmable image zone, whichmay be implemented as part of an image recognition and analysis process,that is configured to differentiate between material and parts of anoperator's body based upon various colors, patterns, shapes, and thelike.

By way of example and not of limitation, the systems, methods, andarticles of manufacture described herein may be implemented to improvethe operational safety of an industrial machine, such as a press brake,to meet all of the operator distance safety requirements in a custombrake metal shop in which the press brake operates. For instance, userspecifications may be selected to raise an upper ram of the press brakeif an image sensor, such as a camera, detects the presence of at leastone pixel in image data collected by the image sensor of a predefinedcolor, such as the color green. The systems, methods, and articles ofmanufacture described herein may also be implemented to monitor theoperation of the industrial machine. For example, where the industrialmachine is a press brake, a number of press brake cycles may bemonitored and/or detected, such that an operating efficiency of thepress brake may be determined.

Although we have described the systems and methods herein being usedwith a press brake machine, it should be understood that the systems andmethods described herein could be used with any machine that requiresthe operator to operate it at a safe distance. For example, the systemsand methods described herein could be used with a drill press, agrinding machine, and the like.

FIG. 1 is a block diagram of an exemplary system 100 for operation of anindustrial machine 102. Broadly, system 100 includes a control system104, an imaging device 106, and a client device 108. System 100 receivespower, in the exemplary embodiment, from a DC power supply of industrialmachine 102, such as through a 5 volt or 12 volt output of industrialmachine 102.

Industrial machine 102 is any industrial machine in which it isdesirable or necessary to monitor and/or protect the safety of anoperator (not shown) of machine 102. For example, in the exemplaryembodiment, industrial machine 102 is a press brake for working sheetmetal. However, in other embodiments, industrial machine 102 is anothermetal working machine, such as a drill press, or any woodworking orother materials working machine.

Industrial machine 102 includes a control box 112 and a switch 114coupled to, controlled by, and/or housed within control box 112. Controlbox 112 houses electrical components, such as one or more processors,one or more tangible, non-transitory, computer-readable storage media,one or more power supplies, and the like for the control of industrialmachine 102.

Switch 114 is any switch capable of halting operation of industrialmachine 102. For example, switch 114 is a three input, three port, orthree lug switch, which may permit an “always open” or “always closed”connection between electrical components. A dual in-line contact member(not shown) is, in some embodiments, coupled to switch 114. As describedherein, switch 114 is coupled to processor 202 as well as to industrialmachine 102 and/or control box 112. In some embodiments, control box 112may house control system 104.

Imaging device 106 is any camera or image capture device capable ofcollecting real time image data. For example, imaging device 106 is anydigital camera, such as any CCD or CMOS camera. Imaging device 106 iscommunicatively coupled to processor 202 and transmits image data toprocessor 202 for analysis.

Imaging device 106 is further located in proximity to industrial machine102 and oriented to collect image data within an image area or imagezone 118. Image zone 118 may define a safety zone or “smart field” aboutindustrial machine 102. As described herein, image zone 118 isreconfigurable on the fly and may be adjusted based upon any of avariety of factors, such as, for example, the particular industrialmachine 102 to be monitored, one or more colors, patterns, and/or shapesto be identified, an area around industrial machine 102 to be monitored,and the like. Further, image zone 118 may include a face of industrialmachine 102 and may extend any desired distance therefrom, such as, forexample, approximately six inches therefrom. In some embodiments, imagezone 118 may include any area around industrial machine 102, any area inproximity or close proximity to industrial machine 102, any areasurrounding industrial machine 102, and the like. Imaging device 106 maythus monitor image zone 118.

Client device 108 is any suitable device capable of displayingoperational data associated with industrial machine 102 and/or receivingcontrol instructions for industrial machine 102. For example, clientdevice 108 may be any computing device, such as any standalone computingdevice, personal computing device, or tablet computing device, anyplasma display, any LED display, and CRT display, any OLED display, andthe like. Client device 108 is communicatively coupled to control system104, such as by a wireless (e.g., BLUETOOTH, WIFI, and the like)connection and/or and wired (e.g., USB, RS232, and the like) connection.

FIG. 2 is a block diagram of control system 104. In general, controlsystem 104 includes at least one processor 202, such as at least onecomputer processor, controller, or logic unit, and a tangible,non-transitory computer-readable storage medium or memory 204. Memory204 includes any type of RAM or ROM, any solid state memory, anyspinning hard drive, any optical computer-readable media, such as a CDor DVD, and the like. Processor 202 is communicatively coupled to memory204. Memory 204 further includes computer-readable instructions that,when executed by processor 202, cause processor 202 to performoperations, as described herein, for operation of industrial machine102, such as operations for halting and/or monitoring industrial machine102.

Processor 202 is also communicatively coupled to imaging device 106,such as by one or more wired or wireless connections, and receives animaging device signal 203 from imaging device 106. In variousembodiments, imaging device signal 203 is any signal output by imagingdevice 106, such as, for example (and as described below), a signalindicating that imaging device 106 has detected the presence of one ormore specified colors, patterns, and/or shapes in image zone 118monitored by imaging device 106 and/or a self-check or no fault foundsignal (as described below) provided by imaging device 106.

Control system 104 also includes a plurality of relay modules, such as afirst relay module 206, a second relay module 208, a third relay module210, and a fourth relay module 212. In the exemplary embodiment, relaymodules 206-212 are any suitable device for electrically isolating oneportion of a circuit from another portion of the circuit or from anothercircuit, such as any relay, any low level trigger optocoupler, anyoptical isolator, any photocoupler, and the like. In some embodiments,relay modules 206-212 may electrically isolate processor 202 fromindustrial machine 102.

In addition, first relay module 206 may be coupled to or cascaded withsecond relay module 208, such that second relay module 208 functions asa redundant relay to first relay module 206. Similarly, third relaymodule 210 may be coupled to or cascaded with fourth relay module 212,such that fourth relay module 210 functions as a redundant relay tothird relay module 208. In addition, in some embodiments, control system104 only includes first relay module 206 and third relay module 210 andexcludes redundant or backup relay modules. In other embodiments,control system 104 includes additional levels of relay redundancy, suchas triple redundant relays or even quadruple redundant relays.

In the exemplary embodiment, first relay module 206 and second relaymodule 208 are coupled to processor 202, such as by one or more wired orwireless connections between first relay module 206, second relay module208, and processor 202. First relay module 206 and second relay module208 may also be coupled to one another, such as, for example, by one ormore wired or wireless connections.

Similarly, third relay module 210 and fourth relay module 212 arecoupled to processor 202, such as by one or more wired or wirelessconnections between third relay module 210, fourth relay module 212, andprocessor 202. Third relay module 210 and fourth relay module 212 mayalso be coupled to one another, such as, for example, by one or morewired or wireless connections.

Thus, processor 202 may communicate a signal, such as a proximity signal214, to one or both of first relay module 206 and/or second relay module208. Likewise, processor 202 may communicate a signal, such as a nofault found signal 216, to one or both of third relay module 210 and/orfourth relay module 212.

In the exemplary embodiment, first relay module 206 may also receive aninput voltage signal 218, such as a 24 volt DC input voltage signal. Asshown, first relay module 206 may transmit or pass input voltage signal218 to second relay module 208. In an alternative embodiment, secondrelay module 208 receives input voltage signal 218 directly and does notreceive input voltage signal 218 from first relay module 206.

In addition, third relay module 210 may receive a machine cycle permitin signal 220, which may be provided by industrial machine 102, and moreparticularly, by control box 112 of industrial machine 102. As shown,third relay module 210 may output machine cycle permit in signal 220 fortransmission to fourth relay module 212. In an alternative embodiment,fourth relay module 212 receives machine cycle permit in signal 220directly and does not receive machine cycle permit in signal 220 fromthird relay module 210.

Thus, first relay module 206 and second relay module 208 each receiveinput voltage signal 218 and proximity signal 214. Similarly, thirdrelay module 210 and fourth relay module 212 each receive machine cyclepermit in signal 220 and no fault found signal 216.

In the exemplary embodiment, and as described in greater detail below,second relay module 208 may generate a machine stop signal 222, andfourth relay module 212 may generate a machine cycle permit out signal224. One or both of machine stop signal 222 and/or machine cycle permitout signal 224 may be communicated (e.g., over a wired or wirelessconnection) to control box 112 of industrial machine 102 for controllingoperation of industrial machine 102. For example, machine stop signal222 may be communicated to control box 112 and/or switch 114 to haltoperation of industrial machine 102, and machine cycle permit out signal224 may be provided to control box 112 and/or switch 114 to permit orallow operation of industrial machine 102.

Control system 104 may be installed in industrial machine 102 duringmanufacture and/or retrofitted with industrial machine 102. In eitherinstance, control system 104 may be spliced into the control circuitryof industrial machine 102. More particularly, industrial machine 102 mayinclude a machine cycle permit wire (not shown), which may be includedwith industrial machine 102 to allow industrial machine to operate orcycle in response to machine cycle permit in signal 220, which may beprovided by a processor or control circuit within control box 112.Similarly, industrial machine 102 may include a machine stop wire (notshown), which may be included with industrial machine 102 to haltindustrial machine in response to machine stop signal 222.

Control system 104 may be spliced into the control circuitry ofindustrial machine 102, such that machine cycle permit in signal 220 isintercepted and provided to third relay module 210, and such thatmachine stop signal 222 is provided by one or both of first relay module206 and/or second relay module 208. In some embodiments, control box 112is also able to provide machine stop signal 222, such as, for example,in response to an action taken by an operator of industrial machine 102.Such an action might be activation of a machine stop button (not shown)on industrial machine 102 by the operator in response to an unsafecondition and/or prior to leaving industrial machine 102, such as, forexample, for a break and/or at the end of the operator's shift.

FIG. 3 is a flowchart illustrating an exemplary process 300 foroperation of industrial machine 100. Accordingly, in the exemplaryembodiment, processor 202 receives fault detection data, such as faultdetection data from imaging device 106 and/or fault detection datagenerated internally by processor 202 (step 302). For instance,processor 202 may generate fault detection data indicating thatprocessor 202 includes a short circuit and/or that software to beexecuted by processor 202 for operation of industrial machine 102 is notloaded or running. Similarly, fault detection data from imaging device106 may indicate that imaging device 106 is not functioning properly oris not powered on.

Processor 202 analyzes the fault detection data (step 304) to determinewhether control system 104 is functional and/or functioning properly(step 306). In the exemplary embodiment, if fault detection data isreceived by processor 202, processor 202 may determine that a fault hasoccurred somewhere within control system 104 and/or within imagingdevice 106. However, if processor 202 does not receive any faultdetection data, processor 202 may determine that control system 104and/or imaging device 106 are functional and/or functioning properly.

If processor 202 determines that control system 104 and/or imagingdevice 106 are functional and/or functioning properly, control system104 may generate and transmit no fault found signal 216 to at least onerelay module, such as third relay module 210 and/or fourth relay module212 (step 308). In the exemplary embodiment, processor 202 transmits nofault found signal 216 to both of third relay module 210 and fourthrelay module 212. However, in other embodiments, only one of third relaymodule 210 and/or fourth relay module 212 receive no fault found signal216.

In addition, and as described above, third relay module 210 may becoupled to fourth relay module 212, which may, in turn, be coupled toswitch 114 of control box 112 (e.g., via a machine permit cycle wire).Third relay module 210 may receive no fault found signal 216 and machinecycle permit in signal 220, and may, in response to receipt of bothsignals 216 and 220, close, such that machine cycle permit in signal 220is output by third relay module 210 to fourth relay module 212. Fourthrelay module 212 may thus receive machine cycle permit in signal 220from third relay module 210 as well as no fault found signal 216 fromprocessor 202.

In response to receipt of both machine cycle permit in signal 220 fromthird relay module 210 and no fault found signal 216 from processor 202,fourth relay module 212 may output machine cycle permit out signal 224,which may be transmitted (e.g., over the machine cycle permit wire) toswitch 114 of control box 112. When switch 114 receives machine cyclepermit out signal 224, switch 114 may close, such that industrialmachine 102 is permitted or allowed to operate. If machine cycle permitout signal 224 is not provided to switch 114, switch 114 may remainopen, and industrial machine may not be allowed to operate. In anotherembodiment, switch 114 may open, rather than close, in response tomachine cycle permit out signal 224. Such an embodiment would requirethat industrial machine 102 operate based upon the absence of machinecycle permit out signal 224. However, such embodiments are contemplatedand within the scope of this disclosure.

Thus, industrial machine 102 may be prevented from functioning bycontrol system 104 until two conditions are met. First, no fault foundsignal 216 must be generated by processor 202, and second, machine cyclepermit in signal 220 must be received by third relay module 210. In thismanner, industrial machine 102 is prevented from operating untilstringent safety requirements are met.

To halt operation of industrial machine 102, as described above, imagingdevice 106 monitors zone 118 to acquire real time (or pseudo real time)image data for zone 118. The real time image data may include one ormore images of image zone 118. Each image is transmitted by imagingdevice 106 to processor 202, which receives the image data (step 310).

Processor 202 analyzes the image data (step 312) to determine whetherthe image data includes at least one of a predefined color, a predefinedpattern, and/or a predefined shape (step 314). For example, the machineoperator may, in the exemplary embodiment, wear a colored glove (notshown) or a glove that is marked with one or more predefined colors,such as the color green. In other words, the glove may be wholly coveredin a particular color or may include markers or areas over which one ormore colors are spread. Processor 202 may execute one or more imagerecognition processes or algorithms for this purpose, which may bestored as software instructions in memory 204.

As the glove of the operator enters zone 118, imaging device 106 maycapture and transmit one or more images of the glove, including thepredefined color of the glove or of one or more areas on the glove, toprocessor 202. In response, processor 202 analyzes the image dataprovided by imaging device 106, identifies the presence of thepredetermined color in the image data, and generates and transmitsproximity signal 214 to first relay module 206 and second relay module208 (step 316). In one embodiment, processor 202 generates and transmitsproximity signal 214 if even a single pixel in the image datacorresponds to the predefined color.

In the exemplary embodiment, processor 202 also analyzes the image datato determine whether the image data includes a predefined pattern and/orshape. More particularly, processor 202 analyzes each of a plurality ofpixels comprising the image as part of a pattern or shape recognitionprocess to identify a pattern or shape, such as a pattern or shapecorresponding to an object or object image (e.g, an appendage of theoperator) in the image data. In response to detecting a pattern and/orshape in the image data, processor 202 generates and transmits proximitysignal 214.

In one embodiment, processor 202 combines color recognition, asdescribed above, with and pattern or shape recognition, as describedabove, such that processor 202 only generates proximity signal 214 inresponse to a determination by processor 202 that the image dataincludes both of a predefined color and a predefined pattern and/orshape.

Similarly, processor 202 may divide image data into a plurality offields or image areas, and each area may be analyzed independently. Insuch an embodiment, processor 202 may, for example, generate proximitysignal 214 in response to a determination that a predefined color,shape, and/or pattern is present in at least one image area but absentfrom at least one other image area.

In the exemplary embodiment, and as described above, proximity signal216 is received by first relay module 206 and second relay module 208,both of which are directly coupled to switch 114 of industrial machine102 (e.g., by a machine stop wire of industrial machine). In response toreceiving proximity signal 214, first relay module 206 generates andoutputs machine stop signal 222. Similarly, in response to receivingproximity signal 214, second relay module 208 generates and outputsmachine stop signal 222. Thus, either or both of first relay module 206and/or second relay module 208 are capable of generating machine stopsignal 222, such that if either relay module 206 and/or 208 receivesproximity signal 216 (indicating that a particular color, pattern,and/or shape, has been detected in the image data), machine stop signal222 is provided to switch 114 of industrial machine 102.

In response to receiving machine stop signal 222, switch 114 may open orclose (e.g., disconnect or connect) to halt all or part of theoperations of industrial machine 102. In the exemplary embodiment,switch 114 is opened. In response, industrial machine 102 shuts downand/or shifts into an open or disengaged position, such that, in thelast instance, the machine operator is able to dislodge any object, suchas the workpiece or an appendage of the operator which may be stuck ortrapped, from industrial machine 102.

Further, in the exemplary embodiment, either or both of the predefinedcolor, pattern, and/or shape are configurable. For instance, computercode or instructions designating one or more colors and/or one or morepatterns and/or shapes may be uploaded to memory 204 for execution byprocessor 202. Thus, system 100 is reconfigurable and updateable as wellas sufficiently flexible for use under a variety of conditions and witha variety of industrial machines 102.

FIG. 4 is a flowchart illustrating an exemplary process 400 formonitoring operation of industrial machine 400. Accordingly, in theexemplary embodiment, processor 202 receives image data from imagingdevice 106 (step 402). As described above, the image data may includeany image data associated with industrial machine 102, such as dataassociated with the operation of industrial machine 102.

In the exemplary embodiment, processor 202 may further analyze the imagedata received from imaging device 106 (step 404). For example, processor202 may determine a number of machine cycles of industrial machine 102occurring within a predefined period of time (e.g., within a fifteenminute period, within a thirty minute period, within a period of onehour, during a shift worked by the operator, and the like). Similarly,processor 202 may determine a number of proximity events associated withindustrial machine 102 that have occurred within a predefined period oftime (e.g., within a fifteen minute period, within a thirty minuteperiod, within a period of one hour, during a shift worked by theoperator, and the like).

Based upon the analysis of the image data, processor 202 may alsogenerate “operational data,” which, as used herein, may include dataassociated with the operation of industrial machine 102 (step 406). Forexample, operational data may be associated with or one or more cyclesof industrial machine 102 (e.g., machine cycles or presses of a pressbrake), data associated with one or more proximity events, and the like.

As used herein, a “proximity event” may be associated with generation ofproximity signal 214, as described above. Thus, a proximity event maycorrespond to detection by processor 202 of a particular pattern, shape,or color in the image data provided by imaging device 106. Such an eventmay indicate, for example, that an operator of industrial machine 102has violated a particular safety protocol, such as by inserting anappendage within image zone 118 during operation of industrial machine102.

Thus, processor 202 may analyze the image data received from imagingdevice 106 to generate operational data corresponding to one or moreevents (e.g., proximity events, machine cycles, and the like) occurringduring operation of industrial machine 102. The operational data mayfurther be associated with or measured over any suitable period of time.

Processor 202 may further transmit the image data (e.g., in real timeand/or pseudo real time) and/or operational data to client device 108(step 408). As described above, client device 108 may be coupled via awired and/or wireless connection to control system 104, such thatprocessor 202 may communicate the operational data via any desirablecommunication mechanism. In addition, processor 202 may communicate theoperational data to client device 108 in any suitable data format, suchas, for example, as part of one or more spreadsheets, as part of one ormore tables, as part of a textual document, as part of an image orcollection of images or image filed, and/or as part of any othersuitable electronic document and/or in any suitable format. Clientdevice 108 may, in response, display the operational data for review andobservation by an operator of client device 108, such as, for example,by a supervisor or manager having responsibility for the operations ofone or more industrial machines 102.

In addition, client device 108 may be configured to receive one or morecontrol instructions, such as one or more control instructions from auser or operator of client device 108. For example, where client device108 includes a computing device, such as a tablet computing device or amobile computing device, a user or operator may provide one or morecontrol instructions via a user interface displayed on client device108. These control instructions may be transmitted by client device 108to control system 104, which may process the instructions to controlindustrial machine 102, such as, for example, to halt industrial machine102, to slow industrial machine 102, to back up industrial machine 102,and the like.

Embodiments of the present disclosure relate to a system, method, andarticle of manufacture for operation of an industrial machine and, moreparticularly, to a system, method, and article of manufacture formonitoring and halting operation of an industrial machine in which animage zone is defined with respect to the industrial machine and inwhich the image zone is monitored for the presence of a predefinedcolor, pattern, and/or shape. To this end, and as described in greaterdetail below, the systems, methods, and articles of manufacturedescribed herein utilize a programmable “smart” field, which may beimplemented as part of an image recognition and analysis process,configured to differentiate between material and parts of an operator'sbody based upon various colors, patterns, shapes, and the like.

Exemplary technical effects of the systems, methods, and articles ofmanufacture described herein include, for example: (a) image zonemonitoring for image analysis and recognition of one or more predefinedcolors, patterns, and/or shapes within the image zone and/or image zone;(b) implementation of a plurality of redundant relays coupled to aprocessor for controlling a machine cycle permit out signal; (c)implementation of a plurality of redundant relays coupled to theprocessor for controlling a machine stop signal; (d) halting of theindustrial machine in response to detection of one or more predefinedcolors, patterns, and/or images; (e) monitoring of the industrialmachine based upon one or more image recognition processes.

Exemplary embodiments of a system, method, and article of manufacturefor halting operation of an industrial machine, and related components,are described above in detail. The system is not limited to the specificembodiments described herein, but rather, components of systems and/orsteps of the methods may be utilized independently and separately fromother components and/or steps described herein. For example, theconfiguration of components described herein may also be used incombination with other processes, and is not limited to practice withthe systems and related methods as described herein. Rather, theexemplary embodiments can be implemented and utilized in connection withmany applications where industrial safety and monitoring systems aredesired.

Although specific features of various embodiments of the presentdisclosure may be shown in some drawings and not in others, this is forconvenience only. In accordance with the principles of the presentdisclosure, any feature of a drawing may be referenced and/or claimed incombination with any feature of any other drawing.

This written description uses examples to disclose the embodiments ofthe present disclosure, including the best mode, and also to enable anyperson skilled in the art to practice the disclosure, including makingand using any devices or systems and performing any incorporatedmethods. The patentable scope of the embodiments described herein isdefined by the claims, and may include other examples that occur tothose skilled in the art. Such other examples are intended to be withinthe scope of the claims if they have structural elements that do notdiffer from the literal language of the claims, or if they includeequivalent structural elements with insubstantial differences from theliteral language of the claims.

What is claimed is:
 1. A control system for operation of an industrialmachine, the control system configured to be spliced into controlcircuitry of the industrial machine to connect the control system to thecontrol circuitry of the industrial machine, the control systemcomprising: a processor; and a tangible, non-transitory,computer-readable memory communicating with the processor, the memoryhaving instructions stored thereon that, in response to execution by theprocessor, cause the processor to perform operations comprising:dynamically configuring at least one of a shape and a size of an imagezone around the industrial machine to which the control system isconnected based upon one or more dimensions of the industrial machine,the image zone being sized to include a portion of the industrialmachine within the image zone; receiving image data from an imagingdevice that monitors the image zone around the industrial machine;analyzing the image data; determining that the control system isfunctional; determining, based upon the analyzing, whether the imagedata includes at least one of a predefined color, a predefined pattern,and a predefined shape; transmitting, in response to determining thatthe image data includes at least one of the predefined color, thepredefined pattern, and the predefined shape, a proximity signal to atleast one first relay module coupled between the processor and theindustrial machine, wherein the at least one first relay module isconfigured to be coupled to a machine stop wire of the industrialmachine to enable the at least one first relay module to halt operationof the industrial machine; and transmitting, in response to determiningthat the control system is functional, a no fault found signal to atleast one second relay module coupled between the processor and theindustrial machine, wherein the at least one second relay module isconfigured to intercept a machine cycle permit wire of the industrialmachine.
 2. The control system of claim 1, wherein halting operation ofthe industrial machine comprises at least one of stopping, partiallystopping, slowing, backing up, and placing the industrial machine in asafe operating condition.
 3. The control system of claim 1, wherein theprocessor performs operations further comprising determining that aplurality of pixels comprising the image data include at least one pixelof the predefined color, and transmitting the proximity signal inresponse to halt operation of the industrial machine.
 4. The controlsystem of claim 3, wherein the predefined color is green.
 5. The controlsystem of claim 1, wherein the processor performs operations furthercomprising dynamically configuring at least one of the predefined color,the predefined pattern, and the predefined shape.
 6. The control systemof claim 1, wherein the processor performs operations further comprisingdetermining that a plurality of pixels comprising the image data areassociated with the predefined shape and the predefined color.
 7. Thecontrol system of claim 6, wherein the predefined shape and thepredefined color are associated with a glove worn by an operator of theindustrial machine.
 8. A control system for operation of an industrialmachine, the control system configured to be connected to controlcircuitry of the industrial machine to connect the control system to thecontrol circuitry of the industrial machine, the control systemcomprising: a processor; and a tangible, non-transitory,computer-readable memory communicating with the processor, the memoryhaving instructions stored thereon that, in response to execution by theprocessor, cause the processor to perform operations comprising:receiving fault detection data indicating whether at least one of theprocessor and an imaging device that monitors an image zone around theindustrial machine is functioning properly; analyzing the faultdetection data; determining, based upon the analyzing, that the controlsystem is functional; transmitting, in response to determining that thecontrol system is functional, a no fault found signal to at least onerelay module of a plurality of relay modules to permit operation of theindustrial machine, wherein the at least one relay module is coupledbetween the processor and the industrial machine and configured tointercept a machine cycle permit wire of the industrial machine;dynamically configuring at least one of a shape and a size of the imagezone around the industrial machine to which the control system isconnected based upon one or more dimensions of the industrial machine,the image zone being sized to include a portion of the industrialmachine within the image zone; receiving image data from the imagingdevice; and controlling, based upon the image data, the industrialmachine, wherein said controlling comprises transmitting a proximitysignal to at least one additional relay module of the plurality of relaymodules coupled to a machine stop wire of the industrial machine to haltoperation of the industrial machine.
 9. The control system of claim 8,wherein the no fault found signal indicates that no fault has beendetected in the control system.
 10. The control system of claim 8,wherein the fault detection data is received from at least one of theimaging device and the processor.
 11. The control system of claim 8,wherein the processor performs operations further comprisingtransmitting the no fault found signal to a plurality of cascaded relaymodules, wherein each relay module of the plurality of cascaded relaymodules are configured to close in response to the no fault foundsignal.
 12. The control system of claim 11, wherein one relay module ofthe plurality of cascaded relay modules is configured to generate amachine cycle permit out signal in response to the no fault foundsignal.
 13. The control system of claim 12, wherein the one relay moduleof the plurality of relay modules is further configured to generate themachine cycle permit out signal in response to a machine cycle permit insignal received from another relay module of the plurality of cascadedrelay modules.
 14. The control system of claim 13, wherein the anotherrelay module of the plurality of relay modules is configured to receivethe machine cycle permit in signal from the industrial machine.
 15. Acontrol system for operation of an industrial machine, the controlsystem configured to be spliced into control circuitry of the industrialmachine to connect the control system to the control circuitry of theindustrial machine, the control system comprising: a processor; and atangible, non-transitory, computer-readable memory communicating withthe processor, the memory having instructions stored thereon that, inresponse to execution by the processor, cause the processor to performoperations comprising: receiving fault detection data indicating whetherat least one of the processor and an imaging device that monitors animage zone around the industrial machine is functioning properly;analyzing the fault detection data; determining, based upon theanalyzing, that the control system is functional; transmitting, inresponse to determining that the control system is functional, a nofault found signal to at least one first relay module coupled betweenthe processor and the industrial machine, wherein the at least one firstrelay module is configured to intercept a machine cycle permit wire ofthe industrial machine; receiving image data from the imaging device;analyzing the image data; determining, based upon the analyzing, whetherthe image data includes at least one of a predefined color and apredefined shape; and transmitting, in response to determining that theimage data includes at least one of the predefined color and thepredefined shape, a proximity signal to at least one second relay modulecoupled between the processor and the industrial machine, wherein the atleast one second relay module is configured to be coupled to a machinestop wire of the industrial machine to enable the at least one secondrelay module to halt operation of the industrial machine.